Concrete structure



Sept. 12, 1944.

R. R. COLBURN CONCRETE STRUCTURE Filed Nov. 6, 1942 INVENTOR.

ZZa/W A TTo/A/gy.

Patented sept. 12, 1944 UNITED STATES PA'I'EN 'r' OFFICE.

4 Claims;

My invention relates generally to improvement in the art of building,and relates more specifically to improvements in concrete structures'andto an improved method of producing such structures.

Generally defined, .an object of the present invention is to provide anew and useful reenforced structure, and an improved method of producingthe same. y

It has heretofore been common and universal practice in the art ofconcrete construction, to utilize either of two standard methods ofproducing re-enforced concrete walls. In accordance with one of theseprior construction methods, sections of the wall were prefabricatedeither in block or slab form suitably reenforced, and the sections weresubsequently assembled and united in various ways to produce the finalwall. This sectional method of construction, while resulting in theproduction of a wall having relatively uniform texture 'and strength,also introduced numerous joints between the sections which were subjectto subsequent cracking and necessitated considerable repair; and inorder to obtain the requisite strength in such sectional walls, it wasalso necessary to make the blocks and slabs rather heavy and bulky. Thenal construction of these pre-fabricated sectional walls also involvedConsiderable skilled labor and other expense, thereby making the cost ofthese prior wall assemblages prohibitive for many purposes. Inaccordance with the other of these prior construction methods,preliminary wooden or metal forms were erected, reenforcing elementswere properly positioned between the forms, and bulk concrete was nallypoured into the forms around the re-enforcement and permitted to set,whereupon the casting forms were removed. Thismethod besides beinglaborious and costly, frequently resulted in the production of wallswhich were not of uniform texture throughout large areas, and theexternal sur- -faces were usually rough and required considerableultimate ilnishing by coating or otherwise in order to provide smoothand presentable nal also due to the bulk and extreme weight of the finalstructures.

It is therefore a more specific object of my present invention toprovide an improved monolithic re-enforced concrete wall structure,which is relatively light but extremely durable in construction, andwhich is also homogeneous in texture throughout its entire area. v

Another'speciflc object of the present invention is to provide asimplified and exceedingly strong building wall or ioor assemblage whichcan be formed primarily of suitably re-enforced concrete, withoutnecessity of utilizing either precast blocks or' slabs, or complicatedand costly pouring forms.

A further specii'lc object of my invention i's to provide a properlyinsulated and re-enforcedconcrete wall which is adapted to be utilized`in conjunction with standard window and door-'assemblages in order toconstruct -attractive and moderately priced buildings.

Still another specicobject of the invention is to provide improvedsupporting and re-enforcing means for concrete wall, ceiling and floorstructures, which can be quickly and conveniently applied, and whichwill subsequently become an integral partvof and prevent undesirysemblages.

surfaces. The casting or pouring method fur-` thermore required the useof relatively skilled labor, and the enclosing forms did not permitinspection of the work until afterthe walls were ilnished and the formshad beenvremoved. Both oi these-prior methods of wall constructiontherefore possess many disadvantages and objections, and cannot beutilized for numerous purposes because of the expense involved and ablecracking or other deterioration of the as- Another specific tureswithout objectionable joints, and with the aid of relatively simpleforms which nally con-fl monolithic re-enforced concrete buildings inany expeditious manner, with least waste of material, and at minimumcost.

Still -another speciiic object of the invention is to provide a new andhighly efficient method of constructing durable jointless one-piecereenforced concrete walls with simplified equipment, and in a mannerwhich will permit unobstructed inspection of all portions of the work atall times. A

These and other specific objects, and advantages of my invention will beapparent from the following detailed description.

A clear conceptionof the various features constituting my presentimprovement, and of the method of producing walls of several typesembodying the invention, may be had by referring object of the presentinverntion is to provide a simpliiled and effective method of producingre-enforced concrete struc--` four inch centers between stud grooves I2isv Fig. 3 is a similarly diagrammatic and fragmentary transversevertical section through a typical floor or ceiling structure utilizingforms and reenforcements similar to that of the wall of Figs. 1 and 2';

Fig. 4 is an enlarged transverse horizontal section through a typicalcorner at the junction of two outer walls such as shown in Fig. 2;

Fig. 5 is a similarly enlarged transverse horizontal section through oneof the columns or studs forming part Aof the improved wall of Fig. 2;

Fig. 6 is a likewise enlarged plan view of one of the re-enforcing rodsupporting/'cleats used in the embodiment of the invention shown inFigs. .1 to 5 inclusive; and

Fig. '7 is a somewhat diagrammatic and fragmentary transverse horizontalsection through a modified type of my improved wall structure.

While the invention has been shown and described herein as beingadvantageously applicable to several types 'of outside lwall assemblagesand to only one form of floor or ceiling construction, it is not mydesire or intention to thereby unnecessarily restrict the scope orutility of the improvement.

The present invention however does have special utility when applied tothe construction of monolithic re-enforced concrete walls, and inaccordance with the improved method, I first erect a single form havingrelatively extensive iiat surfaces lying in a common plane and separatedby Vparallel upright grooves. Thereafter 1 temporarily but firmlyposition \at least'one upright re-enforcing bar or rod parallel andladjacent to each groove but spaced from the form structure. I thenattach a plane layer of foraminous re-enforcing material to the uprightrods in spaced relation to the flat surfaces of the form sections andapproximately parallel to the common plane thereof so that uninterruptedand plane portions of the foraminous layers span each groove. Themonolithic wall is subsequently nally completed and finished byimpacting concrete mixture at high velocity laterally against the flatform surfaces and within the grooves to an extent sufIicient tocompletely embed the rods and the foraminous material'within the layerofconcrete.

Referring specifically to Figs. 1, 2, 4, 5 and 6 of the drawing, thetype of initial backing form shown therein, may be produced primarilyfrom sheets of insulation board or the like of standard twenty-four inchwidth. Each 'of the outer sheets 9 may have a three-inch strip I0removed from one vertical edge thereof, and the sheets 9 and strips I0may thereafter be secured to wooden spacer strips or bars II as shown inFigs. 1 and 2 to form upright parallel recesses or grooves I2separatingrthe outer flat surfaces I3 of the successive sheets 9 whichlie in a common plane. Each of theinner sheets I4 may be maintained atfull twenty-four inch width, and' these sheets I4 may be secured to thewood bars II so as to provide sealed air spaces or chambers I5 betweenthe sheets 9, I4 and the successive stud or column forming grooves I2. Adurable and rigid backing form having twentythus provided.

The next step of my improved method is the attachment of there-enforcing elements to the form assemblage just described, and thismay be readily accomplished with the aid of cleats I6 such as shown inFig. 6. These cleats I6 may be formed of sheet metal, and each cleat hasa triangular portion I1 provided with nail holes I8 and adapted to bebent at right angles to the cleat along a score line I9, and is also'provided with a re-enforcing rod receiving opening 20. The cleats I6may be nailed to the wood bars II in the manner shown in Figs. 4 and 5,with the openings 20 of the successive superimposed cleats in verticalalinement. Upright re-enforc- -sulting from the ing bars or rods 2| maythen be inserted in the alined openings 20, and these rods 2l will befirmly positioned parallel and adjacent tothe grooves I2 but out ofdirect contact with the form. Foraminous re-enforcing material 22 suchas welded wire mesh, in continuous sheet form, may thereafter beattached as by wiring, to the successive parallel rods 2| and also tothe cleats I6 if desired, whereupon the re-enforcing assemblage iscompleted. Care Should be taken to havethe portions of the sheetmaterial 22 which spans the open sides of the grooves I2 insubstantially flat condition and devoid of kinks or indentations.

When the form and re-enforcement assemblage has been thus completed asillustrated in Fig. 1, it is ready for the concrete, and the nalconcrete layer 23 may be impacted against the outer fiat surfaces I3 andwithin the recesses or grooves I2preferably with the aid of compressedair which delivers the fluent concrete mixture in the form of a sprayfrom a portable gun at high velocity. The use of such av spray gunpermits the concrete to be quickly and uniformly applied throughout theentire re-enforced and exposed area, and the use of compressed air as aconveying medium for the concrete aggregate is also advantageous sincethe cooling eiect reexpansion of the suddenly liberated compressed airenhances the drying and setting of the concrete. By virtue of the factthat the concrete receiving form is entirely open and free fromobstruction on the side towhich the y ly visible for inspection, and theoperator is thus able to produce a smooth and finished outer surface 24on the concrete portion of the wall. After the concrete layerl 23 hasbeen applied, the exposed surfaces of the inner sheets I4 may be coatedwith a layer of plastic, paint, or other surfacing material therebycompleting the wall assemblage and producing a simple, compact anddurable monolithic re-enforced concrete wall the strength of which isgreatly enhancedby the successive studs or columns and which will notcrack at the zones of these columns due to the plane and uninterrupteddisposition of the foraminous sheet material 22 across the grooves I2. A

This method of re-enforced wall construction may also be advantageouslyapplied to oors and ceilings of a building, as well as to outer andinner walls, as shown in Fig. 3. Since the walls are verticallydisposed, whereas the floors and ceilings are disposed horizontally, itmay be desirable to additionally re-enforce the latter by making thehorizontal parallel beams or joists heavier and by applying additionalre-enforcement therein. As illustrated in Fig. 3, the depth of thegrooves I2' is increased by using wider spacer strips or bars and modiedcleats I6' areapplied within each ofthe grooves I2. to support anadditional re-enforcing rod 2|?. Otherwise, the floor or ceilingstructuremay be the same as the wall structure, and the concrete layer23 may be applied in the manner previously described to produce asimple, compact and durable monolithic re-enforced concrete floor orceiling of great strength.

While the use of the sheets 9, |4 of insulation board, and of the woodenbars Il, is entirely satisfactory'for producing the improved re-enforcedconcrete structure by the improved method, it may in some cases bedesirable to prefabricate portions 'of the forms and to somewhat enhancethe durability and strength thereof by constructing parts of the formsof metal, plastic, or other material which is stronger than theinsulation board and wooden strips. Such a modied wall assemblage isshown in Fig. 7, whereinV the open sided form is constructed of a seriesof strong pans or plates 25 of interchangeably similar structure, eachhaving oiset flanges 26, 21 at its opposite -vertical edges adapted tooverlap the adjacent flanges 21, 26 of theadjoining sec-v tions orplates 25. The iianges 26, 21,0f the prefabricated plates 25 areprovided with a series of perforations adapted to be brought intoalineconcrete slab, and poured concrete wall structures, are morehomogeneousan'd of uniform texture' throughouttheir entire areas, andcan be lmore rapidly assembled with the new method at greatly reducedcost and with relatively unskilled labor. The improved walls are alsoadaptable to presentbuilding methods and dimensions, by virtue of, thefact that insulation sheets 9, I4, or

pre-fabricated plates of standard widths, may.

be used so as to produce standard distances between the stud or loistcenters, -thereby permitting thev use of standard wooden ormetal -windowand door frames in conjunction with these concrete walls. Because of thefact that the improved forms are one-sidedand are entirely open land-free from obstruction on the side from ment with each other for thereception of eyelbolts 28, andthe coacting-plate flanges may be clampedtogetherv by means of lock nuts 29 coacting Awith the threaded reducedends of the eye-bolts, thus producing the successive stud or columnforming grooves 30 between the alined.

plane outer surfaces 3| of the successive form plates 25. Re-enforcingrods 2| may be inserted within the alined eyes of the superimposedeyebolts 28 and welded wire mesh or other foraminous 're-enforcing sheetmaterial 22 may be ,secured to the rods 2| and eye-bolts 28 in anobvious manner, and a concrete layer 23 may thereafter be impactedagainst the surfaces 3| and within the grooves 30 so as to completelyembed the re-enforcing elements, as previously' described.

In order to provide air chambers or Spaces 32` within walls of themodied type, the extreme inner ends 34 of the eye-bolts 28, beyond thethreading thereon, may be split, and each bolt may be. embraced by aspacer sleeve 33 between the lock nut 29 and the split end 34. Blanket'insulation 35 may then be placed against the outer plate flanges 2l andabout the sleeves 33, whereupon metal lath 36 or other foraminoussheeting may be positioned against the sleeves 33 over the ends of 'theeye-bolts 28 and fastened in place by spreading the split end 34 of.each bolt. 'Ihe modified wall structure may be` finally completed byimpacting or otherwise applying plaster 31 or ne concrete mixtureagainst the metal lath 36 and insulation 35, thus producing'v a simple,strong and extremely compact monolithic re-enforced concrete wallassemblage, which is exceedingly durable and of highly finishedappearance. i

From the foregoing detailed description of several embodiments cf theimprovement, it will be apparent that my present invention provides anwhich the re-enforcing elements are supported, it is easy to apply theconcrete layer 24 uniformly since all portions of the work are at alltimesvisible to the operator, and a smooth final outer surface 24 isalso readily obtainable. Themcde of supporting the 1re-enforcing rods 2|and the disposition of the foraminous sheet material 22 ina planeapproximately parallel to the outer surfaces I3 without irregularitiesat the grooves I2, are also important features of the present invention,and result in the provision of structures which will not crack or weakenat the studs and joists. The use of compressed air in order to impactthe concrete against the forms and around the re-enforcing elements, isalso desirable in order to enhance the speed of construction, andtheimproved cleats I6 may be readily produced at moderate c`ost and can bequickly applied so as to elTectively support the re-enforcement. Theimproved method has :been carried on with a high degree of success, andis adapted to facilitate the construction of buildings of re-enforcedconcrete and at a minimum cost. l

While my improvement has been-shown and described herein as having beenapplied primarily to the construction of outer walls, floors, ceilings,and to one type of corner construction, the'improvedv method isapplicable to the effective construction of interior and exteriorcorners, to the attachment of partitions to walls, to the constructionofinternal partitions, to the formation of upper and lower plates; sills,lintels and other building details. The specific type of hardware usedin applying the method to such details of construction, and of cuttingand fitting variousv c elements without the use of tools, forms no spe-vciflc part of the present application which covers primarily theimproved wall or iloor structure and the method of producing suchstructures'.

It should therefore lbe understood that it is not de'sired to limit'thisinvention to the exact steps of the method or to the precise details ofconstruction of the walls, herein shown and depans to form outwardlyopen approximately upright recesses, clamping elements rmly uniting eachpair of overlapping ilanges and having vertically alined openingsdisposed outwardly beyond said recesses and beyond the common plane ofsaid areas, re-enforcing rods confined within said vertically aimedopenings, ioraminous sheet material suspended solely from said rods andelements and being disposed parallel to and spaced outwardly from saidplane, and a layer of concrete impacted against said pans and concealingsaid elements and rods and foraminous material.

2. A re-enforced concrete wall, comprising, a

series of metallic pans each having a plane area and inwardly oil-setintegral opposite side flanges overlapping the adiacent flanges ofadjoining pans to form outwardly open approximately -upright recesses,insulation sheathing coacting with vertically alined openings,foraminous sheet material suspended solely from said rods and elementsand being disposed parallel to and spaced outwardly from said plane, anda, layer of concrete impacted against said pans and concealing saidelements and rods and foraminous material.

3. A re-enforced concrete wall, comprising, a series of unitary panseach having a plane area and inwardly ofi-set integral opposite sideflanges overlapping the adjacent anges oi' adjoining i pans to formoutwardly open approximately up-,fV right recesses, clamping elementsiirmly uniting each pair of overlapping flanges and having verticallyalined openings disposed outwardly be-/v yond said recesses and beyondthe common plane of said areas, re-enforcing rods confined within saidvertically alined openings, foraminous sheet material suspended solelyfrom said rods and elements and being disposedv parallel to and spacedoutwardly from said plane, and a layer of concrete impacted against saidpans and concealing said elements and rods and foraminous material.

4. A re-enforced concrete wall, comprising, a series of unitary panseach having a plane area and inwardly off-set integral opposite sideanges overlapping the adjacent anges of adjoining pans to form outwardlyopen approximately upright recesses, insulation sheathing coacting withthe inner surfaces of the successive pairs of overlapping -flanges toprovide enclosed air spaces within said pans, clamping elements firmlyuniting e'ach pair of overlapping flanges with each other and with saidsheathing and having vertically alined openings disposed outwardlybeyond said,recesses and beyond the common plane of said areas,re-enforcing rods coniined with said vertically alined openings,foraminous sheet material suspended solely from said rods and elementsand being disposed parallel to and spaced outwardly from said plane, a.layer of concrete impacted against said pans and concealing said flements and rods` and foraminous material, and

a layer of cementitious material disposed against the inner surface ofsaid sheathing.

RICHARD R. COLBURN.

